Composite material manufacturing device and composite material manufacturing method

ABSTRACT

In manufacturing composite material by curing fluid, strength deterioration of the composite material due to repair before the fluid is cured is reduced. A suction hole is formed in a bag film ( 3 ) for sealing a space for fibers being impregnated with resin, after start of impregnation. The suction hole is covered by a plate ( 56 ) with holes ( 57 ). The resin is sucked from the space through the plate ( 56 ). According to such composite material manufacturing method, a defect, which occurs during fibers are impregnated with resin, can be repaired before the resin is cured without causing disorder and damage in the fibers. In a composite material formed from one repaired in the above way, the repaired portion is strong, namely, there is no strength deterioration due to repair after curing, and thus, the material is preferred as compared with a composite material which is repaired after resin is cured.

TECHNICAL FIELD

The present invention relates to a composite material manufacturingdevice and a composite material manufacturing method, and in particular,relates to a composite material manufacturing device and a compositematerial manufacturing method which are used for manufacturing fiberreinforced composite material.

BACKGROUND ART

Fiber reinforced composite material is known which is reinforced withfibers impregnated with resin. The fiber reinforced composite materialis exemplified by CFRP (Carbon Fiber Reinforced Plastics). Since thereis great merit in weight saving, such fiber reinforced compositematerial is applied to products such as aircraft structural members. Asa molding method of the fiber reinforced composite material, there is aVaRTM (Vacuum assisted Resin Transfer Molding) in which laminatedreinforcement fibers are impregnated with resin in a vacuum and theresin is cured. In a fiber reinforced composite material manufactured bythe VaRTM, inherent defects such as a void and impregnation failure ofresin may occur. In general, when the defect in the fiber reinforcedcomposite material is repaired after curing, the strength of therepaired portion is reduced since reinforcement fibers are processed. Acomposite material manufacturing method is desired in which a repair isperformed without reducing strength of a fiber reinforced compositematerial.

Japanese Patent Publication (JP-A-Heisei 07-137154) (conventionalexample 1) discloses a resin composite repair method with extremely-highrepairing effect, capable of filling of resin by performing no orminimum additional process to a product. With respect to the resininjection repair method for resin composite, in a repair method in whichresin is injected into a defect portion of a resin composite having adefect consisting of a void with an opening portion, a connection jigincluding a communicating tube with a valve is attached via a sealant toa surface of the resin composite such that the communicating tubecommunicates with the opening portion in a airtight state, thecommunicating tube is connected to a pressure reducing device to reducepressure in the void of the defect portion, and then resin is injectedfrom the communicating tube.

Japanese Patent Publication (JP-P2003-39455A) (conventional example 2)discloses an RTM method which can easily mold an FRP structure having acomplicated shape or a high-quality FRP structure with no portion ofimpregnation failure. In the RTM method, in which reinforcement basematerial is placed in a molding die having injection ports anddepressurization ports, the upper surface of the molding die is coveredand sealed up with an upper die or bag material, and then resin isinjected from the injection ports while sucking air from thedepressurization ports, when an impregnation failure portion is likelyto remain in a molding product during the molding, the impregnationfailure portion is filled up with resin by switching at least part ofthe depressurization ports to injection ports to inject resin before thecompletion of resin injection.

Japanese Patent Publication (JP-P2004-203021A) (conventional example 3)discloses a resin impregnation sensor/repair device which can easilydetect (monitor) degree of resin impregnation and can repair animpregnation failure defect before resin is cured. The resinimpregnation sensor/repair device has a tube which penetrates a bag filmfor covering fiber base material to be impregnated with liquid resin ina vacuum and to be put into the fiber base material, and a transparentairtight vessel in communication with a base end of the tube.

Japanese Patent Publication (JP-P2005-271247A) (conventional example 4)discloses an FRP reinforce/repair method which can performreinforce/repair operations while restoring shapes and functions beforerepair, and guarantee quality by improving strength properties such asbonding strength and stability of the strength properties whilemaintaining an advantage that degree of freedom of a place of theoperations is high. The FRP reinforce/repair method is characterized inthat the FRP reinforce/repair method at least includes the followingsteps of (A) to (E): (A) a bonding layer covering step for covering witha bonding layer, an outer surface of a defect portion for whichreinforcement and repair of FRP are desired; (B) a preform setting stepfor placing a preform, which at least includes reinforcement fiber basematerial, on the bonding layer; (C) a sealing step for connecting adepressurization suction port and a resin injection port to the preformand covering at least portions of the bonding layer and the preform witha bag material; (D) a resin impregnating step for depressurizing acavity formed in the bag material and injecting resin from the resininjection port to impregnate the preform with resin; and (E) a curingstep for curing the injected resin.

Japanese Patent Publication (JP-P2006-187897A) (conventional example 5)discloses a defect repair method for composite, which can preventdeterioration of after-repair quality and strength of a resin compositeproduct by securely filling a void defect portion formed in the resincomposite product with resin and can deal with various defectsituations. The defect repair method for composite is a defect repairmethod for filling with resin, a void defect portion which has anopening portion and is formed in a resin composite product. The defectrepair method for composite includes: a covering and sealing step forcovering a surrounding region of the opening portion with a flexiblecovering material such that a specific space surrounded by the resincomposite product and the covering material become airtight state; avacuum step for discharging air from the specific space to causepressure in the specific space to be a predetermined vacuum pressure; aresin accumulation process for providing a resin reservoir outside thecovering material to accumulate liquid resin in the resin reservoir suchthat the liquid resin is adjacent to the opening portion across thecovering material; a resin flowing step for making a resin inflow holein a portion of the covering material, which is adjacent to the openingportion, and causing the liquid resin accumulated in the resin reservoirto flow into the void defect portion through the resin inflow hole andthe opening portion due to the vacuum pressure inside the specificspace; and a resin curing step for curing the resin which has flowedinto the void defect portion.

CITATION LIST Patent Literature

-   Patent Document 1: Japanese Patent Publication (JP-A-Heisei    07-137154)-   Patent Document 2: Japanese Patent Publication (JP-P2003-39455A)-   Patent Document 3: Japanese Patent Publication (JP-P2004-203021A)-   Patent Document 4: Japanese Patent Publication (JP-P2005-271247A)-   Patent Document 5: Japanese Patent Publication (JP-P2006-187897A)

SUMMARY OF INVENTION

An object of the present invention is, in manufacturing a compositematerial by curing resin, to provide a composite material manufacturingdevice and a composite material manufacturing method that reducedeterioration of strength of the composite material.

Another object of the present invention is, in manufacturing a compositematerial by curing resin, to provide a composite material manufacturingdevice and a composite material manufacturing method that more securelyrepair the composite material before the resin is cured while reducingdeterioration of strength of the composite material due to the repair.

Still another object of the present invention is, in manufacturing acomposite material by curing resin, to provide a composite materialmanufacturing device and a composite material manufacturing method thatmore securely repair the composite material at lower cost before theresin is cured while reducing deterioration of strength of the compositematerial due to the repair.

A composite material manufacturing method according to the presentinvention includes: a step for forming a suction hole in a bag film forsealing a space in which fibers are impregnated with resin, after astart of impregnation with the resin; a step for covering the suctionhole with a plate in which a plurality of holes are formed; and a stepfor sucking the resin through the plate from the space. According to thecomposite material manufacturing method, it is possible to repair adefect which occurs when fibers are impregnated with resin, withoutcausing disorder and damage in the fibers and before the resin is cured.In a composite material formed from one repaired in the above way, thestrength of the repaired portion is higher, namely, there is no strengthdeterioration due to repair after curing, and thus, the material ispreferred as compared with a composite material which is repaired afterresin is cured.

The composite material manufacturing method according to the presentinvention further includes: a step for forming an injection hole in thebag film; and a step for injecting the resin into the space through theinjection hole during the resin is sucked through the suction hole.According to the composite material manufacturing method, the defectportion can be more securely impregnated with resin.

The composite material manufacturing method according to the presentinvention further includes: a step for sucking the resin through asuction port other than the suction hole; and a step for injecting theresin through an injection port other than the injection hole. It ispreferred that the resin is sucked through the suction hole and theresin is injected into the space through the injection hole during theresin is sucked through the suction port and the resin is injected intothe space through the injection port.

The composite material manufacturing method according to the presentinvention further includes a step for detecting a position in the space,at which a defect occurs, during the resin is sucked through the suctionport and the resin is injected into the space through the injectionport.

The composite material manufacturing method according to the presentinvention further includes a step for closing a hole formed in the bagfilm in the vicinity of the position. The step for sucking the resinthrough the plate is preferred to be performed after the hole is closed.

The composite material manufacturing method according to the presentinvention further includes: a step for forming a large hole in anotherbag film for sealing the space; and a step for sealing the large holewith a bag film after arranging a path medium in the space through thelarge hole. At this time, the injection hole is preferred to be formedin the vicinity of the path medium.

A composite material manufacturing device according to the presentinvention includes: a suction tool set to a suction hole formed in a bagfilm for sealing a space in which fibers are impregnated with resin; anda resin suction device connected to the suction tool through a suctiontube. The suction tool includes: a suction tool main portion in which asuction cavity is formed to be connected to inside of the suction tube;and a suction porous portion in which a plurality of holes are formed toconnect the cavity and the space. The resin suction device sucks theresin through the suction porous portion. The composite materialmanufacturing device can suck the resin impregnated into the fiberswithout causing disorder and damage in the fibers. As a result, thecomposite material manufacturing device can repair a defect which occursduring the fibers are impregnated with resin before the resin is cured.In a composite material formed from one repaired in the above way, thestrength of the repaired portion is higher, namely, there is no strengthdeterioration due to repair after curing, and thus, the material ispreferred as compared with a composite material which is repaired afterresin is cured.

The composite material repair device according to the present inventionincludes: an injection tool set to an injection hole formed in the bagfilm; and a resin injection device connected to the injection toolthough an injection tube. The injection tool includes: an injection toolmain portion in which an injection cavity is formed to be connected toinside of the injection tube; and an injection porous portion in which aplurality of holes are formed to connect the injection cavity and thespace. The resin injection device injects the resin into the spacethrough the injection porous portion. When a defect, which occurs duringfibers are impregnated with resin, is repaired before the resin iscured, the composite material manufacturing device can securely causethe defect portion to be impregnated with resin.

The suction tool can be used as the injection tool. At this time, theinjection tool and the suction tool can be manufactured at lower cost.

A tool according to the present invention includes: a main portion inwhich a cavity is formed; a joint portion connected to a tube to connectthe cavity to inside of the tube; and a porous portion. When the tool isset to a bag film for sealing a space in which fibers are impregnatedwith resin, the porous portion is arranged between the cavity and thespace. In the porous portion, there are formed a plurality of holesconnecting the cavity and the space to each other. According to thetool, it is possible to repair a defect which occurs when fibers areimpregnated with resin, without causing disorder and damage in thefibers and before the resin is cured. In a composite material formedfrom one repaired in the above way, the strength of the repaired portionis higher, namely, there is no strength deterioration due to repairafter curing, and thus, the material is preferred as compared with acomposite material which is repaired after resin is cured.

When composite material is manufactured by curing resin, the compositematerial manufacturing device and the composite material manufacturingmethod according to the present invention can repair the compositematerial without strength deterioration before the resin is cured.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a sectional view showing a composite material forming tool;

FIG. 2 is a block diagram showing a composite material manufacturingdevice which is set to the composite material forming tool when a voidis detected;

FIG. 3 is a block diagram showing a composite material manufacturingdevice which is set to the composite material forming tool when animpregnation failure portion is detected;

FIG. 4 is a block diagram showing a composite material manufacturingdevice which is set to the composite material forming tool when arelatively-large impregnation failure portion is detected;

FIG. 5 is a perspective view showing a suction tool;

FIG. 6 is a sectional view showing the suction tool;

FIG. 7 is a flow chart showing a composite material manufacturingmethod;

FIG. 8 is a flow chart showing a composite material manufacturing methodfor a case that a void is detected;

FIG. 9 is a flow chart showing a composite material manufacturing methodfor a case that an impregnation failure portion is detected; and

FIG. 10 is a flow chart showing a composite material manufacturingmethod for a case that a relatively-large impregnation failure portionis detected.

DESCRIPTION OF EMBODIMENTS

With reference to the attached drawings, a composite materialmanufacturing device according to the present invention will bedescribed. FIG. 1 is a sectional view showing a configuration of acomposite material manufacturing device according to an embodiment ofthe present invention. The composite material manufacturing device 1according to the embodiment includes a composite material forming toolhaving a mold 2 and an injection-side path medium 5. As shown in FIG. 1,the mold 2 has a plate portion 7 and lateral portions 8. The plateportion 7 is made of metal, composite material, or resin, in the shapeof a plate such that a composite material to be formed has a desiredshape. The plate portion 7 defines a bottom portion of the mold 2. Thelateral portions 8 are attached onto the plate portion 7. Thus, thelateral portions 8 define lateral portions of the mold 2. Although notshown in the figure, the lateral portions 8 are formed at four sides onthe plate portion 7 to form an impregnation space having an opening onthe upper side. The shapes of the lateral portions 8 on the plateportion 7 determine a rough planar shape of the composite material to bemanufactured. Additionally, changes in heights of the lateral portions 8determine a rough shape of the composite material in a direction ofheight. Fiber reinforcement 10 to be impregnated is placed in theimpregnation space. After that, the mold 2 is sealed up with a bag film3.

The mold 2 is further provided with an injection port 11 and a suctionport 12. The injection port 11 penetrates the lateral portion 8 toconnect a resin injection device (not shown) and the impregnation spaceof the mold 2. The resin injection device injects resin into theimpregnation space through the injection port 11. The suction port 12connects a resin suction device (not shown), and the impregnation space.The resin suction device performs vacuum evacuation of the sealedimpregnation space through the suction port 12, and sucks the injectedresin from the impregnation space to the outside.

It is also possible that the mold 2 is configured not to use the lateralportions 8. In this case, an impregnation space is an internal spacewhich is sealed up by the plate portion 7 and the bag film 3, and inwhich the fiber reinforcement 10 to be impregnated is placed. Theinjection port 11 connects the impregnation space and the resininjection device (not shown), and the suction port 12 connects theimpregnation space and the resin suction device (not shown).

Alternatively, the lateral portions 8 may be made of flexible materialor material of undefined shape. For example, rubber, wax, plasticmaterial, and sealant are available.

The injection-side path medium 5 is formed in the form of a net at thebottom of the impregnation space, and assists resin to be injectedevenly from the resin injection device into the impregnation spacethrough the injection port 11. In this example, the path medium 5 may beprovided not at the bottom of the impregnation space but at the upperportion. In that case, it is preferable that the injection port 11 isalso positioned at the upper portion and connected to the path medium 5.

The fiber reinforcement 10 includes a fiber portion. In the fiberportion, woven fabrics made of carbon fiber are laminated. Note that thefiber portion may also be made of another fiber other than carbon fiber,such as glass fiber and aramid fiber.

As shown in FIG. 2, a void 21 can be formed in a fiber reinforced resinintermediate material 22 to be manufactured, when the fiberreinforcement 10 is impregnated with resin. The void 21 includes minutegas bubbles. The void 21 tends to be formed when a volatile component isincluded in injected resin or when a leak hole 23 is formed in the bagfilm 3.

Additionally, an impregnation failure defect can be formed in the fiberreinforced resin intermediate material 22 at the resin impregnation. Theimpregnation failure defect is a portion in which carbon fiber is bareddue to insufficient resin impregnation. FIG. 3 shows the fiberreinforced resin intermediate material 22 in which the impregnationfailure portion 41 is formed.

Furthermore, a relatively-large impregnation failure defect can beformed in the fiber reinforced resin intermediate material 22. FIG. 4shows the fiber reinforced resin intermediate material 44 in which therelatively-large impregnation failure portion 43 is formed. Theimpregnation failure portion 43 is formed in the fiber reinforced resinintermediate material 22 in the vicinity of the bag film 3.

As shown in FIG. 1, the composite material manufacturing device 1further includes an inspection device 20 for inspecting the presence ofvoid or impregnation failure defect. The inspection device 20, forexample, is an imaging device and takes an image of the impregnationspace from above to detect a void or a defect based on the image whenthe bag film 3 is transparent. Additionally, it is preferable that theinspection device 20 should be able to recognize plane positioncoordinates of the impregnation space and report a position of a void orthe like. When the impregnation space is large, the inspection device 20may be moved on plane coordinates and detect position coordinates inconjunction with the movement. Additionally, the inspection device 20may be a nondestructive inspection device such as an ultrasonic testdevice. According to this, it is possible to detect not only a defect onthe surface but also a void or the like at the inside. It is preferablethat the inspection device 20 should be able to operate not only aftercompletion of impregnation but also during impregnation process.

Processes will be described for a case when the void 21 is detected asshown in FIG. 2.

The composite material manufacturing device 1 includes a suction tool32, a resin suction device 33, a suction tube 34, an injection tool 35,a resin injection device 36, and an injection tube 37. After resinimpregnation is started, for example during the resin impregnation, anopening is formed in the bag film 3 and the suction tool 32 is attachedto the opening. The resin suction device 33 is connected to the suctiontool 32 through the suction tube 34. After resin impregnation isstarted, for example during the resin impregnation, an opening is formedin the bag film 3 and the injection tool 35 is attached to the opening.The resin injection device 36 is connected to the injection tool 35through the injection tube 37.

As shown in FIG. 2, when the void 21 is detected in the fiber reinforcedresin intermediate material 22, the suction tool 32 is positioned on thebag film 3 in the vicinity of a position at which the void 21 is formed.When the void 21 is detected, the injection tool 35 is positioned on thebag film 3 in the vicinity of the position at which the void 21 isformed. The injection tool 35 is positioned such that a distance betweenthe position of the void 21 and the injection tool 35 is longer than adistance between the position of the void 21 and the suction tool 32.

After the leak hole 23 of the bag film 3 is closed, the resin suctiondevice 33 is operated by a user to perform evacuation of theimpregnation space through the suction tool 32 and the suction tube 34,and suck resin from the impregnation space to the outside. The resininjection device 36 is operated by the user to inject resin into theimpregnation space through the injection tool 35 and the injection tube37. As a result, the void is filled up with resin. At this time, resinmay be injected into the impregnation space through the injection port11, and vacuum evacuation may be performed to the sealed impregnationspace through the suction port 12. Alternatively, the injection of resinthrough the injection port 11 and the evacuation through the suctionport 12 may be stopped or completed.

As shown in FIG. 3, there is a case that the inspection device 20detects an impregnation failure defect in the fiber reinforcement 10,which is formed in resin impregnation. The impregnation failure defectis a portion in which carbon fiber is bared due to insufficient resinimpregnation. When the impregnation failure portion 41 is detected inthe fiber reinforced resin intermediate material 22, an opening isformed in the bag film 3 at the position corresponding to a center ofthe region in which the impregnation failure portion 41 is formed, andthe suction tool 32 is placed at the opening. When the impregnationfailure portion 41 is detected in the fiber reinforced resinintermediate material 22, openings are formed in the bag film 3 at aplurality of positions corresponding to a periphery of the region inwhich the impregnation failure portion 41 is formed, and the injectiontools 35 are placed at the openings. The resin suction device (notshown) connected to the suction tube 34 is operated by the user toevacuate the impregnation space and suck resin from the impregnationspace to the outside through the suction tool 32 and the suction tube34. The resin injection device (not shown) connected to the injectiontubes 37 is operated by the user to inject resin into the impregnationspace through the injection tools 35 and the injection tubes 37. As aresult, the impregnation failure portion 41 is impregnated with resin.At this time, resin may be injected into the impregnation space throughthe injection port 11, and vacuum evacuation may be performed to thesealed impregnation space through the suction port 12. Alternatively,the injection of resin through the injection port 11 and the evacuationthrough the suction port 12 may be stopped or completed.

Furthermore, the inspection device 20 may detect formation of arelatively-large impregnation failure defect. FIG. 4 shows the fiberreinforced resin intermediate material 22 in which the relatively-largeimpregnation failure portion 43 is formed. The impregnation failureportion 43 is formed in the fiber reinforced resin intermediate material22 in the vicinity of the bag film 3. At this time, the bag film 3 iscut away such that the large impregnation failure defect portion isexposed. As shown in FIG. 4, the composite material manufacturing device1 further includes a bag film 46, a sealant 47, and a path medium 48.The bag film 46 covers a hole formed in the bag film 3 in the vicinityof the impregnation failure portion 43 correspondingly to theimpregnation failure portion 43. The sealant 47 is positioned in the gapbetween the bag film 46 and the remaining bag film 3, and contactstightly both of the bag film 46 and the bag film 3. The sealant 47 sealsup the gap between the bag film 46 and the bag film 3 to preventcontaminant from entering inside of the mold 2. The path medium 48 ispositioned at a side of the impregnation space from the bag film 46 andpositioned in a region in which the impregnation failure portion 43 isformed.

The injection tool 35 is positioned on the bag film 46 at a center ofthe region in which the impregnation failure portion 43 is formed. Thesuction tool 32 is positioned on the bag film 46 at a periphery of theregion in which the impregnation failure portion 43 is formed, i.e.positioned in a region in which the path medium 48 is arranged.

As mentioned above, the suction tool 32 is positioned at a place whereresin impregnation is expected to occur at last. For this reason, theposition of the suction tool 32 may vary depending on conditions of thedefect.

The resin suction device 33 (not shown) is operated by the user toevacuate the impregnation space through the suction tool 32 and thesuction tube 34 and suck resin from the impregnation space to theoutside. The resin injection device 36 (not shown) is operated by theuser to inject resin into the impregnation space through the injectiontool 35 and the injection tube 37. As a result, the impregnation failureportion 43 is impregnated with resin. At this time, resin may beinjected into the impregnation space through the injection port 11, andvacuum evacuation may be performed to the sealed impregnation spacethrough the suction port 12. Alternatively, the injection of resinthrough the injection port 11 and the evacuation through the suctionport 12 may be stopped or completed.

FIG. 5 shows the suction tool 32. The suction tool 32 includes a mainportion 51 and a joint portion 52. The main portion 51 is made ofaluminum and formed in the shape of a cylindrical shape. The jointportion 52 is made of aluminum and has a cylindrical shape of whichdiameter is smaller than that of the cylinder of the main portion 51.The joint portion 52 is joined to a bottom surface portion of thecylinder of the main portion 51 such that the joint portion 52 isintegrated with the main portion 51. The suction tool 32 may be made ofanother metal such as stainless steel.

As shown in FIG. 6, a cavity 55 is formed inside the main portion 51. Aflow path 53 is formed in the joint portion 52. The flow path 53connects the outside to the cavity 55. The suction tool 32 furtherincludes a porous plate portion 56. The porous plate portion 56, forwhich rigidity is necessary, is made of stainless steel, and a pluralityof holes 57 are formed in the porous plate portion 56. That is to say,the porous plate portion 56 is made from perforated metal. The porousplate portion 56 is positioned at a bottom surface of the cylinder ofthe main portion 51, opposite to the bottom surface on which the jointportion 52 is formed. The holes 57 of the porous plate portion 56connect the impregnation space to the cavity 55 at the time of use. Notethat the porous plate portion 56 may be replaced by another plate withmany holes. The other plate is a wire mesh, for example. It is alsopossible to use a block-shaped member having a plurality of holes forconnecting the impregnation space to the cavity 55 at the time of use,instead of the porous plate portion.

The suction tool 32, when used, is bonded to the bag film 3 by applyinga double-sided tape 58 to the bottom surface of the main portion 51, andsealant 59 is provided to the bottom of the main portion 51 for sealingup the bonding portion. The double-sided tape 58 bonds a surroundingportion of the suction tool 32, which surrounds the porous plate portion56, to a surrounding portion surrounding a hole 61 formed in the bagfilm 3. The double-sided tape 58 can be replaced by another tool forbonding the surrounding portion surrounding the porous plate portion 56and the surrounding portion surrounding the hole 61. The other tool isadhesive, for example. The sealant 59 tightly contacts both of thesurrounding portion surrounding the porous plate portion 56 and thesurrounding portion surrounding the hole 61. The sealant 59 seals up agap between the suction tool 32 and the bag film 3 to preventcontaminant from entering inside of the mold 2 through the gap and thehole 61, and prevent vacuum leak.

The injection tool 35 is made in the same way as the suction tool 32.That is to say, the injection tool 35 includes a main portion and ajoint portion. The main portion is made of aluminum and formed in acylindrical shape. The joint portion is made of aluminum and formed in acylindrical shape of which diameter is smaller than that of the cylinderof the main portion. The joint portion is joined to a bottom surface ofthe cylinder of the main portion such that the joint portion isintegrated with the main portion. A cavity is formed inside of the mainportion. A flow path is formed in the joint portion. The flow pathconnects the outside to the cavity. The injection tool 35 furtherincludes a porous plate portion. The porous plate portion is made ofstainless steel, and a plurality of holes are formed in the porous plateportion. The porous plate portion is positioned at a bottom surface ofthe cylinder of the main portion, opposite to the bottom surface onwhich the joint portion is formed. The holes of the porous plate portionconnect the impregnation space to the cavity. The injection tool 35,when used, is bonded to the bag film by applying a double-sided tape tothe bottom surface of the main portion, and sealant is provided to thebottom of the main portion for sealing up the bonding portion. Thedouble-sided tape bonds a surrounding portion of the injection tool 35,which surrounds the porous plate portion, to a surrounding portionsurrounding a hole formed in the bag film. That is to say, thedouble-sided tape can be replaced by another tool for bonding thesurrounding portion surrounding the porous plate portion and thesurrounding portion surrounding the hole. The other tool is adhesive,for example. The sealant tightly contacts both of the surroundingportion surrounding the porous plate portion and the surrounding portionsurrounding the hole. The sealant seals up a gap between the injectiontool 35 and the bag film 3 to prevent contaminant from entering insidethe mold 2 from the gap through the hole 61, and prevent vacuum leak.

Since the injection tool 35 and the suction tool 32 have the same shapeand the same function as mentioned above, one of the tools can be usedas the other.

A composite material manufacturing method according to the embodiment ofthe present invention is carried out by using the composite materialmanufacturing device 1. The user firstly laminates a plurality of sheetsformed by carbon fiber, as shown in FIG. 7 (step S1). Next, theinjection-side path medium 5 is positioned inside of the mold 2, and theplurality of sheets are positioned on the path medium 5. After that, theimpregnation space of the mold 2 is sealed up from the outside by usingthe bag film 3 (step S2). Furthermore, the injection port 11 and thesuction port 12 are formed, the injection port 11 is connected to theresin injection device, and the suction port 12 is connected to theresin suction device.

The composite material manufacturing device 1 is placed in an oven,while heating the composite material manufacturing device 1, the resininjection device is used to inject resin into the impregnation space ofthe mold 2 and the resin suction device is used to evacuate theimpregnation space of the mold 2. After the resin reaches the suctionport 12, the resin is discharged from the mold 2 to the outside by usingthe resin suction device (step S3). As a result of the injection ofresin, the fiber reinforced resin intermediate material 22 is formedfrom the laminated sheets.

While injecting the resin into the impregnation space of the mold 2, theinspection device 20 is used to inspect the fiber reinforced resinintermediate material 22 whether or not a defect is present (step S4).When it is judged that a defect is present in the fiber reinforced resinintermediate material 22 (step S4, defect is found), the fiberreinforced resin intermediate material 22 is repaired (step S5).

When it is judged that no defect is present in the fiber reinforcedresin intermediate material 22 (step S4, no defect is found), or afterthe fiber reinforced resin intermediate material 22 is repaired, thefiber reinforced resin intermediate material 22 is formed into fiberreinforced resin by curing the resin through heating it at highertemperature (step S6). The fiber reinforced rein is inspected whether adefect is present (step S7), and the fiber reinforced resin is completedwhen no defect is found in the fiber reinforced resin.

FIG. 8 shows a method carried out in the step S5 when the void 21 isfound in the step S4 of the composite material manufacturing method inFIG. 7. The method is carried out by using the composite materialmanufacturing device 1, and carried out in parallel (simultaneously)with the step S3 of the composite material manufacturing method in FIG.7. First, the bag film 3 is inspected to detect a leak point (hole 23)which has caused the void (step S11), and the detected hole 23 is closed(step S12).

Next, a suction hole is formed at a position of the bag film 3, at whichthe void 21 is formed (step S13). The diameter of the suction hole isslightly smaller than the diameter of the bottom surface of the suctiontool 32. The double-sided tape 58 is used to bond the surroundingportion of the suction tool 32, which surrounds the porous plate portion56, to the surrounding portion which surrounds the suction hole formedin the bag film 3. Next, the sealant 59 is used to seal the gap betweenthe suction tool 32 and the bag film 3 to prevent contaminant fromentering inside of the mold 2 from the gap. Furthermore, the suctiontube 34 is used to connect the suction tool 32 and the resin suctiondevice 33 (step S14).

The injection tool 35 is set to the bag film 3, in the same way as thesuction tool 32. That is to say, an injection hole is formed in the bagfilm 3 at a position corresponding to and in the vicinity of a positionat which the void 21 is formed. At this time, the injection hole isformed such that a distance between the position of the void 21 and theinjection hole is longer than a distance between the position of thevoid 21 and the suction hole. The diameter of the injection hole isslightly smaller than the diameter of the bottom surface of theinjection tool 35. The double-sided tape is used to bond the surroundingportion of the injection tool 35, which surrounds the porous plateportion, to the surrounding portion which surrounds the injection holeformed in the bag film 3. Next, the sealant is used to seal the gapbetween the injection tool 35 and the bag film 3 to prevent contaminantfrom entering inside of the mold 2 from the gap. Furthermore, theinjection tube 37 is used to connect the injection tool 35 and the resininjection device 36.

The resin suction device 33 is used to evacuate the inside of the mold 2through the suction tool 32, and suck the resin from the impregnationspace of the mold 2 through the suction tool 32 (step S15). The resininjection device 36 is used to inject resin into the impregnation spaceof the mold 2 through the injection tool 35 (step S16). After resin issucked through the suction tool 32 from the fiber reinforced resinintermediate material 22 in which the void 21 is formed to the outside,the injection of resin through the injection tool 35 is stopped and thesuction of resin through the suction tool 32 is stopped.

According to the composite material manufacturing method, it is possibleto repair a void which occurs in the fiber reinforced resin intermediatematerial 22 when fibers are impregnated with resin, without causingdisorder and damage in the fiber portion and before the resin is cured.A composite material formed from the material repaired in the above wayis preferred as compared with a composite material which is repairedafter the resin is cured, since the strength of the repaired portion ishigher in the composite material formed from the material repaired inthe above way.

Note that the composite material manufacturing method can be carried outwithout setting the injection tool 35 to the bag film 3 when a region inwhich a void is formed is small enough. At this time, a region fromwhich resin is sucked through the suction tool 32 is filled with resinpositioned in the surroundings, and a shortage of resin is compensatedby injection of resin into the inside of the mold 2 through theinjection port 11. Such composite material manufacturing method can, assame in the case that the composite material manufacturing method iscarried out while injecting resin into the inside of the mold 2 throughthe injection tool 35, repair the fiber reinforced resin intermediatematerial 22 without causing disorder and damage in the fiber portion andreduce deterioration of the strength of a repaired portion of acomposite material formed from the repaired fiber reinforcement 10.

FIG. 9 shows a composite material manufacturing method carried out inthe step S5 when the impregnation failure portion 41 is found in thestep S4 of the composite material manufacturing method in FIG. 7. Thecomposite material manufacturing method is carried out by using thecomposite material manufacturing device 1 while the step S3 of thecomposite material manufacturing method in FIG. 7 is carried out. Asuction hole is formed at the center of the region of the bag film 3, inwhich the impregnation failure portion 41 is formed (step S21). Thediameter of the suction hole is slightly smaller than the diameter ofthe bottom surface of the suction tool 32. The double-sided tapes 58 isused to bond the surrounding portion of the suction tool 32 surroundingthe porous plate portion 56 to the surrounding portion surrounding thesuction hole formed in the bag film 3. Next, the sealant 59 is used toseal the gap between the suction tool 32 and the bag film 3 to preventcontaminant from entering inside of the mold 2 from the gap.Furthermore, as shown in FIG. 3, the suction tube 34 is used to connectthe suction tool 32 and the resin suction device 33 (not shown) (stepS22).

In the same way as the suction tool 32, the injection tool 35 is set tothe bag film 3. That is to say, an injection hole is formed at aperiphery of the region of the bag film 3, in which the impregnationfailure portion 41 is formed. The diameter of the injection hole isslightly smaller than the diameter of the bottom surface of theinjection tool 35. The double-sided tapes is used to bond thesurrounding portion of the injection tool 35 surrounding the porousplate portion to the surrounding portion surrounding the injection holeformed in the bag film 3. Next, the sealant is used to seal the gapbetween the injection tool 35 and the bag film 3 to prevent contaminantfrom entering inside of the mold 2 from the gap. Furthermore, theinjection tube 37 is used to connect the injection tool 35 and the resininjection device 36 (not shown). When the impregnation failure portion41 is large, it is also possible to set a plurality of injection tools35 to the bag film 3.

The resin suction device 33 is used to evacuate the impregnation spaceof the mold 2 through the suction tool 32 and suck resin from theimpregnation space of the mold 2 through the suction tool 32 (step S23).The resin injection device 36 is used to inject resin into the inside ofthe mold 2 through the injection tool 35 (step S24). After resin inwhich the impregnation failure portion 41 is formed is sucked from themold 2 to the outside of through the suction tool 32, the injection ofresin through the injection tool 35 is stopped and the suction of resinthrough the suction tool 32 is stopped.

According to the composite material manufacturing method, it is possibleto repair an impregnation failure portion which occurs in the fiberreinforced resin intermediate material 22 when fibers are impregnatedwith resin, without causing disorder and damage in the fiber portion andbefore the resin is cured. A composite material formed from the materialrepaired in the above way is preferred as compared with a compositematerial which is repaired after the resin is cured, since the strengthof the repaired portion is higher in the composite material formed fromthe material repaired in the above way.

Note that the composite material manufacturing method can be carried outwithout setting the injection tool 35 to the bag film 3 when a region inwhich an impregnation failure occurs is small enough. At this time, aregion from which resin is sucked through the suction tool 32 is filledwith resin positioned in the surroundings, and a shortage of resin iscompensated by resin injected into the inside of the mold 2 through theinjection port 11. Such composite material manufacturing method can, assame in the case that the composite material manufacturing method iscarried out while injecting resin into the inside of the mold 2 throughthe injection tool 35, repair the fiber reinforcement 10 without causingdisorder and damage in the fiber portion and reduce deterioration of thestrength of a repaired portion of a composite material formed from therepaired fiber reinforced resin intermediate material 22.

FIG. 10 shows a composite material manufacturing method carried out inthe step S5 when a relatively large impregnation failure portion 43 isfound in the step S4 of the composite material manufacturing method inFIG. 7. The composite material manufacturing method is carried out byusing the composite material manufacturing device 1 while the step S3 ofthe composite material manufacturing method in FIG. 7 is carried out.First, a hole is formed in the bag film 3 such that the impregnationfailure portion 43 is exposed (step S31). The path medium 48 is setthrough the formed hole such that the path medium 48 is positioned in aregion in which the impregnation failure portion 43 is formed (stepS32). The hole formed in the bag film 3 is covered by the bag film 46,and the sealant 47 is used to contact tightly the bag film 46 and thebag film 3 to each other and seal up the gap between the bag film 46 andthe bag film 3 (step S33).

An injection hole is formed at the center of the region of the bag film46, in which the impregnation failure portion 43 is formed. The diameterof the injection hole is slightly smaller than the diameter of thebottom surface of the injection tool 35. The double-sided tape 58 isused to bond the surrounding portion of the injection tool 35surrounding the porous plate portion 56 to the surrounding portionsurrounding the suction hole formed in the bag film 46. Next, thesealant 59 is used to seal the gap between the injection tool 35 and thebag film 46 to prevent contaminant from entering inside of the mold 2from the gap. Furthermore, as shown in FIG. 4, the injection tube 37 isused to connect the injection tool 35 and the resin injection device 36(not shown) (step S34).

Additionally, the suction tool 32 is set to the bag film 46, in the sameway as the injection tool 35. That is to say, a suction hole is formedat a position in the bag film 46, in which the path medium 48 islocated. The diameter of the suction hole is slightly smaller than thediameter of the bottom surface of the suction tool 32. The double-sidedtape is used to bond the surrounding portion of the suction tool 32surrounding the porous plate portion 56 to the surrounding portionsurrounding the suction hole formed in the bag film 46. Next, thesealant is used to seal the gap between the suction tool 32 and the bagfilm 46 to prevent contaminant from entering inside of the mold 2 fromthe gap. Furthermore, the suction tube 34 is used to connect the suctiontool 32 and the resin suction device 33 (not shown).

The resin suction device 33 is used to evacuate the impregnation spaceof the mold 2 through the suction tool 32 and suck resin from theimpregnation space of the mold 2 through the suction tool 32 (step S35).The resin injection device 36 is used to inject resin into the inside ofthe mold 2 through the injection tool 35 (step S36). After resin inwhich the impregnation failure portion 43 is formed is sucked from themold 2 to the outside through the suction tool 32, the injection ofresin through the injection tool 35 is stopped and the suction of resinthrough the suction tool 32 is stopped.

According to the composite material manufacturing method, it is possibleto repair the relatively-large impregnation failure portion 43 whichoccurs in the fiber reinforced resin intermediate material 22 whenfibers are impregnated with resin, without causing disorder and damagein the fiber portion and before the resin is cured. A composite materialformed from the material repaired in the above way is preferred ascompared with a composite material which is repaired after the resin iscured, since the strength of the repaired portion is higher in thecomposite material formed from the material repaired in the above way.

Note that the above-mentioned composite material manufacturing methodcan be carried out as a repair method, after injection of resin into theimpregnation space through the injection port 11 is completed. At thistime, a region from which resin is sucked through the suction tool 32 isfilled with resin positioned in the surroundings, and a shortage ofresin is compensated by injection of resin into the impregnation spacethrough the injection tool 35. Furthermore, an injection tool 35 can benewly added when resin is insufficient. The composite material repairmethod may be carried out simultaneously with the time when thecomposite material manufacturing method is carried out while injectingresin into the impregnation space of the mold 2 through the injectionport 11. The composite material repair method can, as same as themanufacturing method, repair the fiber reinforcement 10 without causingdisorder and damage in the fiber portion, and can reduce deteriorationof the strength of a repaired portion of a composite material formedfrom the repaired fiber reinforcement 10.

The invention claimed is:
 1. A composite material manufacturing methodcomprising: injecting resin through an injection port into animpregnation space sealed by a bag film to impregnate fibers with theresin; sucking the resin through a suction port; forming a suction holedifferent from the suction port in the bag film for a non-impregnationportion; attaching a suction tool to the suction hole, the suction toolhaving a porous portion in which a plurality of holes are formed; andsucking the resin through the porous portion from the impregnationspace.
 2. The composite material manufacturing method of claim 1,further comprising: forming an injection hole in the bag film; andinjecting the resin into the impregnation space through the injectionhole during said sucking the resin through the suction hole.
 3. Thecomposite material manufacturing method of claim 2, wherein the resin issucked through the suction hole and the resin is injected into theimpregnation space through the injection hole while the resin is suckedthrough the suction port and the resin is injected into the impregnationspace through the injection port.
 4. The composite materialmanufacturing method of claim 3, further comprising: detecting aposition of the non-impregnation portion in the impregnation space. 5.The composite material manufacturing method of claim 4, furthercomprising closing a hole formed in the bag film at a positioncorresponding to the position of the non-impregnation portion, whereinsaid sucking the resin through the porous portion is performed aftersaid hole is closed.
 6. The composite material manufacturing method ofclaim 1, further comprising: sealing the impregnation space by coveringan opening formed in the bag film with another bag film.
 7. Thecomposite material manufacturing method of claim 1, wherein the suctiontool has a passage for conveying resin, and the porous portion extendsacross an entire cross section of the passage.
 8. A composite materialmanufacturing method comprising: injecting resin through an injectionport into an impregnation space sealed by a bag film to impregnatefibers with the resin; sucking the resin through a suction port; forminga suction hole different from the suction port in the bag film adjacentto a non-impregnation portion of the fibers, the non-impregnationportion being a portion of the fibers having a failure of resinimpregnation; attaching a suction tool to the suction hole, the suctiontool having a porous portion in which a plurality of holes are formed;sucking the resin through the porous portion from the impregnationspace; and during said sucking the resin through the porous portion,impregnating the non-impregnation portion with the resin.
 9. Thecomposite material manufacturing method of claim 7, further comprising:forming an injection hole in the bag film; and injecting the resin intothe impregnation space through the injection hole during said suckingthe resin through the suction hole.
 10. The composite materialmanufacturing method of claim 8, wherein the resin is sucked through thesuction hole and the resin is injected into the impregnation spacethrough the injection hole while the resin is sucked through the suctionport and the resin is injected into the impregnation space through theinjection port.
 11. The composite material manufacturing method of claim9, further comprising: detecting a position of the non-impregnationportion in the impregnation space.
 12. The composite materialmanufacturing method of claim 10, further comprising closing a holeformed in the bag film at a position corresponding to the position ofthe non-impregnation portion, wherein said sucking the resin through theporous portion is performed after said hole is closed.
 13. The compositematerial manufacturing method of claim 7, further comprising: sealingthe impregnation space by covering an opening formed in the bag filmwith another bag film.
 14. The composite material manufacturing methodof claim 7, wherein the suction tool has a passage for conveying resin,and the porous portion extends across an entire cross section of thepassage.